X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=filamentspool.scad;h=55da1ac7324eb27a81e7bf1aae1f0eab5ddc893b;hp=eb4ee6d30a9b7f3bbbc74d9c9f93c6bd6caab1da;hb=469554b15dfb0ea23ba7f29f7067cc04a81c259a;hpb=c4191f131e15cd12517feaa0cd0ada40fb3b4e1d

diff --git a/filamentspool.scad b/filamentspool.scad
index eb4ee6d..55da1ac 100644
--- a/filamentspool.scad
+++ b/filamentspool.scad
@@ -1,27 +1,378 @@
+// -*- C -*-
+
+fdia=1.75;
 
 slop=0.5;
+bigslop=slop*2;
+
+exteffrad = 70;
+hubeffrad = 30;
+hubbigrad = 20;
+hublwidth = 3;
+hubstemwidth = 2;
+hublthick = 10;
+hubaxlelen = 25;
+hubaxlerad = 5;
+totalheightfromtower = 240;
+axletowerfudgebend = 0;
+axleaxlefudgebend = 3;
+axlepadlen = 1.0;
 
 prongthick=5;
 prongwidth=5;
-ratchetstep=10;
+ratchetstep=15;
 ratchettooth=3;
 ratchettoothheight=5;
+ratchettoothsmoothr=1;
+ratchettoothslope=0.75;
 overlap=0.5;
+cupbigrad=20;
+
+xstraightmul = 1.75;
+
+propxshift = 0;
+
+doveclipheight = 10;
+
+teethh=3;
+teethgapx=4+fdia;
+
+prongstalkxwidth=3;
+
+stalklength=35;
+overclipcupgap=5;
+overclipdepth=15;
+overcliproundr=2.0;
+overclipthick=0.5;
+
+overclipsmaller=-2.5;
+overclipbigger=0.0;
+
+wingspoke=3;
+wingsize=6;
+wingthick=3;
 
 armendwallthick=2.5;
 armendbasethick=1.2;
 
-module ArmEnd(length=100){
-  channelwidth = prongthick + slop;
-  channeldepth = prongwidth + ratchettoothheight;
-  totalwidth = armendwallthick*2 + channelwidth;
-  totalheight = channeldepth + armendbasethick;
+axlehorizoffset = 12.5;
+axlevertheight = 100;
+towercliph = 16;
+towerclipcount = 3;
+towerpillarw = 5;
+
+axlepinrad = 2;
+axlepintabrad = 5;
+
+washerthick = 1.2;
+washerthinthick = 0.8;
+washerverythinthick = 0.4;
+washerrad = hubaxlerad + 7.5;
+frictionwasherarmwidth = 3;
+frictionwasherextrapush = 1.0;
+
+ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
+
+include <doveclip.scad>
+include <cliphook.scad>
+include <filamentteeth.scad>
+
+channelwidth = prongthick + slop;
+channeldepth = prongwidth + ratchettoothheight;
+totalwidth = armendwallthick*2 + channelwidth;
+totalheight = channeldepth + armendbasethick;
+stalkwidth = prongwidth + prongstalkxwidth;
+
+module ArmEnd(length=120){ ////toplevel
+  translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
+    rotate([0,0,-90])
+      DoveClipPairBase(h=doveclipheight);
+  }
+
   difference(){
     translate([0, -armendwallthick, -armendbasethick])
-      cube([ratchetstep+overlap, totalwidth, totalheight]);
+      cube([length, totalwidth, totalheight]);
     translate([-1, 0, 0])
-      cube([ratchetstep+overlap+2, channelwidth, channeldepth+1]);
+      cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
+    translate([-1, 0, ratchettoothheight])
+      cube([length+2, channelwidth, channeldepth+1]);
+  }
+  for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
+    translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
+      rotate([90,0,0])
+	cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
+      multmatrix([	[	1, 0, ratchettoothslope, 0	],
+			[	0,	1,	0,	0	],
+			[	0,	0,	1,	0	],
+			[	0,	0,	0,	1	]])
+	cube([ratchettooth - ratchettoothsmoothr*2,
+	      channelwidth, ratchettoothheight - ratchettoothsmoothr]);
+    }
+  }
+}
+
+module FilamentCupHandle(){
+  pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
+  mirror([0,1,0]) {
+    cube([stalklength, stalkwidth, prongthick]);
+    translate([stalklength, stalkwidth/2, 0])
+      cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
+    translate([ratchettoothsmoothr, stalkwidth, 0]) {
+      minkowski(){
+	cylinder($fn=20,r=ratchettoothsmoothr, h=1);
+	multmatrix([	[	1, -ratchettoothslope, 0, 0	],
+			[	0,	1,	0,	0	],
+			[	0,	0,	1,	0	],
+			[	0,	0,	0,	1	]])
+	  cube([pawlusewidth,
+		ratchettoothheight - ratchettoothsmoothr,
+		prongthick - 1]);
+      }
+    }
+  }
+}
+
+module FilamentCupCup(){
+  xstraight = cupbigrad * xstraightmul;
+  linear_extrude(height=prongthick) {
+    FlatArc(0,0, cupbigrad,cupbigrad+prongwidth, 89,271, $fn=80);
+  }
+  for (my=[0,1]) mirror([0,my,0]) {
+    translate([0,cupbigrad,0])
+      cube([xstraight, prongwidth, prongthick]);
   }
 }
 
-ArmEnd();
+module FilamentCup() { ////toplevel
+  FilamentCupHandle();
+
+  dx = cupbigrad + prongwidth;
+  gapy = prongwidth;
+  dy = cupbigrad + gapy + overclipcupgap;
+
+  translate([dx, dy, 0])
+    FilamentCupCup();
+  translate([0, -1, 0]);
+  cube([prongwidth, dy+1, prongthick]);
+
+  midrad = cupbigrad + prongwidth/2;
+
+  propshift = stalklength - overclipdepth - prongthick + propxshift;
+  proptaken = propshift;
+  echo(cupbigrad, dx, midrad, propshift, proptaken);
+
+  translate([propshift, -1, 0]) {
+    // something is wrong with the y calculation
+    cube([prongwidth,
+	  dy - sqrt(midrad*midrad - proptaken*proptaken) - prongwidth/2,
+	  prongthick]);
+  }
+  translate([0, overclipcupgap, 0])
+    rotate([0,0, 102 + fdia])
+    FilamentTeeth(fdia=fdia, h=teethh);
+}
+
+module CupSecuringClipSolid(w,d,h1,h2){
+  rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
+    polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
+  }
+}
+
+module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
+  hbase = totalheight + prongstalkxwidth - overcliproundr*2;
+  minkowski(){
+    CupSecuringClipSolid(w=totalwidth,
+			 d=overclipdepth + xdepth,
+			 h1=hbase - overclipsmaller,
+			 h2=hbase + overclipbigger);
+    cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
+  }
+}
+
+module CupSecuringClip(){ ////toplevel
+  wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
+  difference(){
+    union(){
+      CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
+      translate([-wingswidth/2, -wingsize/2, 0])
+	cube([wingswidth, wingsize, wingthick]);
+    }
+    translate([0,0,-0.1])
+      CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
+  }
+}
+
+module ArmDoveClipPin(){ ////toplevel
+  DoveClipPin(h=doveclipheight);
+}
+
+module TowerDoveClipPin(){ ////toplevel
+  DoveClipPin(h=towercliph/2);
+}
+
+module Hub(){ ////toplevel
+  difference(){
+    cylinder($fn=60, h=hublthick, r=hubbigrad);
+    translate([0,0,-1])
+      cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
+  }
+  axlerad = hubaxlerad + slop;
+  difference(){
+    cylinder(h=hubaxlelen, r=axlerad+hublwidth);
+    translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
+  }
+  hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
+  holewidth = DoveClipPairSane_width() - hubstemwidth*2;
+  for (ang=[0,120,240])
+    rotate([0,0,ang]) {
+      difference() {
+	translate([hubeffrad,0,0])
+	  DoveClipPairSane(h=doveclipheight,
+			   baseextend = (hubeffrad - DoveClip_depth()
+					 - hubbigrad + hublwidth));
+	if (hole>hublwidth && holewidth > 2) {
+	  translate([hubbigrad + hublwidth, -holewidth/2, -1])
+	    cube([hole, holewidth, hublthick+2]);
+	}
+      }
+    }
+  xmin = axlerad+hublwidth/2;
+  xmax = hubbigrad-hublwidth/2;
+  for (ang = [0 : 60 : 359])
+    rotate([0,0,ang]) rotate([90,0,0]) {
+      translate([0,0,-hublwidth/2])
+	linear_extrude(height=hublwidth)
+	polygon([[xmin,0.05], [xmax,0.05],
+		 [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
+    }
+}
+
+module ArmExtender(){ ////toplevel
+  DoveClipExtender(length=exteffrad-hubeffrad,
+		   ha=doveclipheight,
+		   hb=doveclipheight);
+}
+
+module AxlePin(){ ////toplevel
+  pinr = axlepinrad - slop;
+  intersection(){
+    translate([0, 0, pinr*0.7]) {
+      translate([0, -washerrad, 0]) rotate([-90,0,0])
+	cylinder(r=pinr, h=washerrad*2, $fn=10);
+      translate([-axlepintabrad, hubaxlerad, -axlepinrad])
+	cube([axlepintabrad*2, axlepinrad*2, axlepinrad*2]);
+    }
+    translate([-50,-50,0]) cube([100,100,50]);
+  }
+}
+
+module Axle(){ ////toplevel
+  pillarswidth = DoveClipPairSane_width(towerclipcount);
+
+  rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
+  translate([-axlehorizoffset, -axlevertheight, 0]) {
+    rotate([0,0,-axletowerfudgebend])
+    rotate([0,0,-90])
+      DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
+    translate([0, DoveClip_depth(), 0])
+    rotate([0,0,90])
+      ExtenderPillars(axlevertheight - DoveClip_depth(),
+		      pillarswidth, towercliph,
+		      pillarw=towerpillarw);
+  }
+
+  axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
+  axlerad = hubaxlerad-slop;
+  bump = axlerad * 0.2;
+  shift = axlerad-bump;
+  joinbelowallow = 3;
+
+  intersection(){
+    translate([0, 0, shift]) {
+      difference() {
+	union(){
+	  translate([-1, 0, 0])
+	    rotate([0,90,0])
+	    cylinder($fn=60,
+		     r = axlerad,
+		     h = 1 + axleclearlen + axlepinrad*2 + 2);
+	  mirror([1,0,0]) rotate([0,90,0])
+	    cylinder(r = axlerad*1.75, h = 3);
+	  intersection(){
+	    mirror([1,0,0])
+	      translate([axlehorizoffset - pillarswidth/2, 0, 0])
+	      rotate([0,90,0])
+	      cylinder($fn=60,
+		       r = towercliph - shift,
+		       h = pillarswidth);
+	    translate([-50, -joinbelowallow, -50])
+	      cube([100, joinbelowallow+50, 100]);
+	  }
+	}
+	rotate([90,0,0])
+	translate([axleclearlen + axlepinrad/2, 0, -25])
+	  cylinder(r = axlepinrad + slop, h=50);
+      }
+    }
+    translate([-50,-50,0]) cube([100,100,100]);
+  }
+}
+
+module washer(thick){
+  difference(){
+    cylinder(h=thick, r=washerrad);
+    translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
+  }
+}
+
+module AxleWasher(){ ////toplevel
+  washer(thick=washerthick);
+}
+
+module AxleThinWasher(){ ////toplevel
+  washer(thick=washerthinthick);
+}
+
+module AxleVeryThinWasher(){ ////toplevel
+  washer(thick=washerverythinthick);
+}
+
+module AxleFrictionWasher(){ ////toplevel
+  difference(){
+    cylinder(h=washerthick, r=washerrad);
+    translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
+  }
+  frarmr = hubbigrad;
+  frarmw = frictionwasherarmwidth;
+  frarmpawlr = hublwidth;
+  frarmpawlpush = slop*4 + frictionwasherextrapush;
+  for (ang=[0,180]) rotate([0,0,ang]) {
+    translate([washerrad-1, -frarmw/2, 0])
+      cube([frarmr - washerrad + 1, frarmw, washerthick]);
+    intersection(){
+      translate([frarmr - frarmpawlr, -50, 0])
+	cube([frarmpawlr, 100, 50]);
+      rotate([0,90,0])
+	cylinder(h = 50, r = frarmpawlpush, $fn=36);
+    }
+  }
+}
+
+module TowerExtender(){ ////toplevel
+  l = totalheightfromtower - axlevertheight;
+  echo("TowerExtender",l);
+  DoveClipExtender(length = l,
+		   ha = towercliph, hb = towercliph,
+		   counta = towerclipcount, countb = towerclipcount,
+		   pillarw = towerpillarw);
+}
+
+//ArmEnd();
+//FilamentCup();
+//CupSecuringClip();
+//Hub();
+//ArmExtender();
+//Axle();
+//AxleWasher();
+//AxlePin();
+//AxleFrictionWasher();